2363-IC-AA / BA

FoCuS ST INTERCooLER
Tools required: INSTALLATIoN
Screwdriver / trim tool, torx set, socket set, allen keys INSTRuCTIoNS

STEP 1: With the bonnet open, use a trim tool, or similar, remove the top panel
fixing screws.

STEP 2: Disconnect the bonnet release cable and then withdraw the top cover
STEP 3: Remove the two headlight locating screws on both headlights

STEP 4: Pull the headlight’s upwards to remove it from its mount.

You’ll need to disconnect the plug as shown
STEP 5: With the car safely raised on a ramp / axle stands undo the offside
(UK models) wheel arch liner as shown

STEP 6: A) Undo and remove the lower deflector B) Remove the rear section of the undertray
C) Undo and remove the corner deflector as shown

A B

C
STEP 7: Undo the two bumper bolts (by headlights). Then unclip the front bumper from the
wing on both sides

STEP 8: You’ll need two people to withdraw the bumper assembly - you’ll need to
disconnect the fog light (located on RHS) before the bumper can be fully removed

REF: The front of the car should now look similar to the shot below.
STEP 9: Pull the top air duct free from its mounting locators

STEP 10: Undo the two torx screws holding the lower air duct (as indicated by the
yellow arrows) manouver free from clips at the bottom and withdraw

STEP 11: You’ll now have access to the ‘active grill shutter’ - this needs to be removed
later but at this point push the blades to ensure it’s in the fully closed position
STEP 12: Undo the jubilee clips holding the boost pipes on both sides of the intercooler

STEP 13: Unclip the MAP sensor as shown

STEP 14: Undo the two intercooler retaining 8mm bolts

STEP 15: Disconnect the horn plug as shown

STEP 16: Use a trim tool, or similar, to free horn loom mounting clip
STEP 17: Undo the horn bracket mounting bolt and withdraw the horn assembly

STEP 18: Remove the boost pipe hoses from both sides of the intercooler...

... The intercooler will then be free to be removed

STEP 19: Remove the MAP sensor from the end of the intercooler

STEP 20: Re-fit this to the new intercooler as shown. Note: US intercoolers will require
an additional bracket (supplied) to hold the MAP sensor in the correct orientation

Eu spec uS spec

REF: Please note the orientation and arrangement of the intercooler mounting brackets
STEP 21: Disconnect the active grill shutter connector shown

STEP 22: Using a trim tool, or similar, free the AGS loom

STEP 23: Manouver the AGS free of the two clips on either side and then remove
the complete assembly
REF: The front of the vehicle should now look like this (US vehicles may vary slightly)

STEP 24: Insulate the AGS loom connector that’s still remaining...

... and position it securely - a suitable location can be seen below

STEP 25: Using a trim tool, or similar, free the locating mount for the horn loom

STEP 26: Feed the horn loom back under the headlight - towards the wheel arch liner

STEP 27: Use a bottle jack or suitable stand to take the weight of the radiator / cradle
STEP 28: Remove the radiator cradle bolts on both sides

STEP 29: Position the mountune intercooler into place (you will need two people)

STEP 30: The side brackets fit underneath the radiator cradle as shown in STEP 30 and 31
STEP 31: Tighten the cap-head bolts but leave a little play to help positon the intercooler

STEP 32: Ensure the intercooler is sitting as far to the left as possible; get someone
to hold this in position...

... then fully tighten the cap head bolts. Note: the shorter bolt is used on the LHS
STEP 33: Refit the boost pipes and tighten the jubilee clips. Re-fit the MAP sensor connector

STEP 34: Using the supplied horn bracket, arrange the horn assembly as shown, re-connect
the horn loom

STEP 35: Re-fit the original upper air deflector, front bumper and undertrays

Fitting Ends